Wound film dispenser with exterior retainer and method for manufacturing same

ABSTRACT

A wound film dispenser with exterior retainer and method of assembling same are disclosed. The wound film dispenser includes a base to which a lid is hingedly attached via a fold. The interior end walls of the base include false walls which are biased into the base. The false walls include aperture through which the ends of the roll extend to at least partially receive the ends of the roll of wound film material. In so doing, the retainers are provided exterior to the roll of film. The false walls may be biased into the base using braces pushing the top edge of the false wall away from the end walls.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part of U.S. patentapplication Ser. No. 09/711,017, filed on Nov. 13, 2000.

FIELD OF THE INVENTION

[0002] The invention generally relates to dispensers and, moreparticularly, relates to dispensers for use in conjunction with woundfilms such as plastic wrap, aluminum foil, wax paper, and the like.

BACKGROUND OF THE INVENTION

[0003] Cartons for the storage and dispersal of rolls of wound flexiblefilm are well-known. Such cartons are typically manufactured frompaperboard material and are folded into a configuration conventionallyreferred to as a trunk-lid box wherein a base or box of the carton formsan enclosure for the roll with an open top, and the lid is foldedrelative to the trunk at a natural hinge to thereby allow the lid toclose the trunk.

[0004] A number of criteria need to be considered when manufacturingsuch a carton. One concern is the ease with which the material can bedrawn from the roll. This criteria is a function of a number ofvariables including the type of material wound onto the roll, the mannerin which the roll is positioned or placed within the carton, and theangle at which the material must be pulled from the carton. For example,if the material is highly adhesive in nature, it may tend to adhere toitself thereby requiring a relatively high level of force to pull thematerial from the roll. Depending upon the degree of tack of the film,and the angle at which the material is pulled from the carton, the rollitself may tend to be pulled completely out of the carton, creating asource of frustration for the user. Morever, once the roll is pulledfrom the carton, the risk of contamination of the film is increased.

[0005] Mechanisms have therefore been devised which perform a retentionfeature within the carton. In other words, the roll itself may bephysically held within the carton such that upon a user pulling on thefilm, the roll is held against the force created by the user, whilestill enabling the roll to rotate and thereby dispense film. Forexample, U.S. Pat. No. 4,998,656, assigned to the present assignee,discloses a roll restraining dispensing carton wherein the opposite endsof the carton include collars for retaining the roll within the carton.The collars include apertures which circumnavigate the ends of the rollto thereby physically hold the roll within the carton, and also providea bearing surface around which the roll may rotate.

[0006] While such cartons have proven to be successful, it would beadvantageous to continue to improve roll retention and dispensingcapabilities. Moreover, since such cartons are typically manufacturedand loaded with rolls of wound film in an automated process, it would beadvantageous to improve the ease with which the carton is manufacturedas well.

SUMMARY OF THE INVENTION

[0007] In accordance with one aspect of the invention, a wound filmdispenser is provided which comprises a base, a lid, and retentionwalls. The base includes bottom, left, right, front, and back walls, andan open top defining an interior channel. The lid is hingedly attachedto the base. The retention walls are mounted in the first and secondends of the base and each include an aperture adapted to receive an endof the roll of wound film. The retention walls are each non-parallel tothe end walls.

[0008] In accordance with another aspect of the invention, a wound filmdispenser is provided which comprises a base, a cover hinged to thebase, a roll of wound film within the base, and means for retaining theroll within the base. The means includes false walls biased into thebase.

[0009] In accordance with another aspect of the invention, a method ofassembling a wound film dispenser is provided comprising the steps offolding a section of die-cut material into a tube, inserting a roll ofwound film into the tube, folding false walls into the tube, and foldingat least one flap against each of the false walls. The tube includesfirst and second open ends, a top surface, a bottom surface, a frontsurface, and a back surface. The false walls include apertures receivingends of the wall, as well as braces engaging the flaps and biasing thefalse walls into the tube.

[0010] These and other aspects and features of the invention will becomemore apparent upon reading the following detailed description when takenin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is an isometric view of a wound film dispenser constructedin accordance with the teachings of the invention, with a roll of woundfilm held therein;

[0012]FIG. 2 is an isometric view of the wound film dispenser of FIG. 1,but without a roll of wound film disposed therein;

[0013]FIG. 3 is a longitudinal sectional view of the film dispenser ofFIG. 1 taken along line 3-3 of FIG. 1 with the roll of film shown inpartially cut-away form;

[0014]FIG. 4 is an enlarged cut-away top view of the dispenser of FIG.1;

[0015]FIG. 5 is a plan view of a die-cut blank prior to foldingaccording to the teachings of the invention;

[0016]FIG. 6 is a flow chart depicting a sample sequence of steps whichmay be employed to construct a wound film dispenser constructed inaccordance with the teachings of the invention;

[0017]FIG. 7 is an isometric view of an alternative roll film dispenserconstructed in accordance with the teachings of the invention and shownwith a roll of wound film disposed therein;

[0018]FIG. 8 is a longitudinal sectional view of the dispenser of FIG. 8taken along line 8-8 of FIG. 7, with the roll of film shown in partiallycut-away form;

[0019]FIG. 9 is an enlarged cut-away top view of the dispenser of FIG.8; and

[0020]FIG. 10 is a plan view of a die-cut blank prior to foldingaccording to the teachings of the invention.

[0021] While the invention is susceptible to various modifications andalternative constructions, certain illustrative embodiments thereof havebeen shown in the drawings and will be described below in detail. Itshould be understood, however, that there is no intention to limit theinvention to the specific forms disclosed, but on the contrary, theintention is to cover all modifications, alternative constructions, andequivalents falling within the spirit and scope of the invention asdefined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Referring now to the drawings, and with specific reference toFIG. 1, a film dispenser constructed in accordance with the teachings ofthe invention is generally depicted by reference numeral 20. As showntherein, the film dispenser 20 includes a base 22 to which a lid 24 isnaturally hinged at a fold 26. The base 22 defines an interior channel28 in which a roll 30 of wound web material 32 is positioned. In thepreferred embodiment, the base 22 and lid 24 are manufactured from anintegral piece of material such as paperboard, chipboard, cardboard,corrugated board, micro-fluted board, or the like, and is folded andjoined in a series of consecutive steps as will be described in furtherdetail herein to form the film dispenser 20. In one preferredembodiment, the material may be provided in the form of twenty-fourpoint single ply chipboard, but other materials, including chipboardhaving a lesser point count, are certainly possible.

[0023] With reference now to FIGS. 2-5, the carton 20 is depicted bothwith and without a roll 30 provided therein. The base 22 includes abottom wall 34, a front wall 36, a back wall 38 and first and secondends 40, 42. The lid 24 includes a top wall 44, a front wall 46, andfirst and second ends 48, 50. The roll 30 includes a core 52 (FIG. 3)around which is wound the web of film 32. Film 32 may be, but is notlimited to plastic wrap, aluminum foil, wax paper and the like. A cutterbar 43 may be provided anywhere on dispenser 20 for severing wrap 32,such as on bottom wall 34, or preferably on an inside surface of the lidfront wall 46.

[0024] As shown in FIGS. 3 and 4, each of the ends 40, 42 of the base 22includes a retainer 56 adapted to retain the roll 30 within thedispenser 20. More specifically, the retainers 56 at least partiallysurround first and second ends 58, 60 of the core 52 to physically holdthe roll 30 in the dispenser 20. The retainers 56 do so with, amongother things, reduced material requirements as compared to priordispensers.

[0025] In one embodiment, the retainer 56 may be provided in the form ofa false wall 62 angled into the interior channel 28. FIG. 3 indicatesthat the false wall 62 is biased into the interior channel 28 at anangle ∝ relative to the ends 40, 42, but it is to be understood thatalternative embodiments may angle the false wall 62 differently, or fromdifferent surfaces within the dispenser 20 including, but not limitedto, the back wall 38.

[0026] In the depicted embodiment, the false wall 62 extends from a basesection 63 (FIG. 5) hinged to the bottom wall 34 of the base 22 and isangularly biased inwardly by a brace 64. The brace 64 extends from aback edge 66 of the false wall 62. The brace 64 is substantiallywedge-shaped including a top edge 68, a tapered side edge 70 and astraight edge 72. While the brace 64 is indicated to be proximate theback wall 38, it is to be understood that in alternative embodiments,the brace 64 could be provided, for example, proximate the front wall 36as well. The brace 64 is preferably not adhered to the back wall 38, butrather relies on the outward bias afforded by the roll 30, forcing thestraight edge 72 into engagement with the first and second ends 40, 42of the base 22. Given the angle of the tapered edge 66, the false wall62 is angled in an identical fashion. In alternative embodiments, thebrace 64 and/or false wall 62 may be adhered into an angled position.

[0027] As shown best in FIGS. 4 and 5, the false wall 62 furtherincludes an aperture 76. In the depicted embodiment, the aperture 76 issubstantially semi-circular in shape and is adapted to receive the firstand second ends 58, 60 of the core 52. As shown in FIG. 3, the apertures76 do not receive the entire ends 58 and 60 of the core 52, but ratheronly partially receive the core 52 therethrough. Alternatively, if thefalse walls 62 and/or dispenser 20 are enlarged, and the core 52lengthened, the ends 58, 60 may be entirely received within the falsewalls 62.

[0028]FIG. 4 further depicts the multiple end flaps of the dispenser 20completing the end walls 40, 42. With regard to the base 22, a majorflap 80 extends from each end of the back wall 38, while a minor flap 82extends from each end of the front wall 36. It is to be understood thatthe major and minor flaps 80, 82 may be attached to opposite walls, maybe provided in opposite dimension, or may be provided in similardimension. Similarly, with respect to the lid 24, a major flap 84extends from each end of the top wall 44, while a minor flap 86 extendsfrom each end of the front wall 46.

[0029] Completing the sections of the dispenser 20, it will be notedthat a tear strip 88 is attached along a score line 90 to an outer edge92 of the lid front wall 46. As will be discussed in further detailherein, during assembly the dispenser 20 is formed by folding a blank 94(FIG. 5) into a tube and securing the tear strip 88 to the trunk frontwall 36. Adhesive may be applied to plurality of scored areas 96 to notonly secure the dispenser 20, but facilitate removal of the tear strip88 when desired without defacing the remainder of the dispenser 20.

[0030] In assembling wound film dispensers according to the teachings ofthe invention, a number of steps may be employed. One exemplary set ofsteps is depicted in FIG. 6 in flow chart format. As shown therein, afirst step 98 may be to die-cut the blank 94 as depicted in FIG. 5. Asecond step 100 may be to fold the blank 94 into a tube having first andsecond open ends, meaning that the false wall 62, and the end flaps 80,82, 84 and 86 are not folded inwardly and secured. The roll 30 is theninserted into the tube as indicated by a step 102. The roll 30 ispreferably inserted in an automated fashion by, for example, sliding theroll along a bottom wall 34 a set distance, or until a proximity sensor,or other form of position sensor, is triggered.

[0031] Once the roll 30 is inserted, the assembly of the end walls 40,42 is commenced by folding the brace 64 normal to the false wall 62 andfolding the false wall 62 into the tube, as indicated by a step 104. Inso doing, the ends 58, 60 of the core 52 are captured, thereby retainingthe roll 30 within the dispenser 20. The minor flap 82 is then foldedinwardly, as indicated in a step 106, to be adjacent the false wall 62.The minor flap 82 may be adhered to the false wall 62 once folded. Thebase 22 is completed upon folding of the major flap 80, as indicated ina step 108. The major flap 80 is adhered parallel to the minor flap 82creating the ends 40, 42. As illustrated in FIGS. 2 and 3, when thedispenser 20 is assembled, the brace 64 engages the ends 40, 42, biasingthe false walls 62 angularly inward.

[0032] The dispenser 20 is completed upon folding of minor flap 86 andmajor flap 84 of the lid 24, as indicated in a step 110. Morespecifically, as shown best in FIG. 2, the minor flap 86 is foldednormal to the lid top wall 44, and major flap 84 is then folded parallelthereto and adhered into position. In so doing, the dispenser 20 iscompleted, substantially enclosing the roll 30 and protecting the roll30 from contamination. Even after opening, i.e., removal of the tearstrip 88, the lid 24 provides closed ends cooperating with the closedends of the base 22 to substantially enclose the roll 30.

[0033] Referring now to FIGS. 7-10, an alternative embodiment of a woundfilm dispenser constructed in accordance with the teachings of theinvention is depicted. Wherein like elements are employed, likereference numerals are used. One difference with respect to thealternative embodiment of FIGS. 6 and 7 is provided in the form of thebrace. As depicted therein, the brace 97 of the alternative embodimentextends from a top edge 98 of the aperture 76. The brace 97 issubstantially polygonal in shape including a front edge 100, back edge102, and first and second side edge 104, 106. The brace 64 is foldedaway from the false wall 62 so as to allow the front edge 100 todirectly engage the ends 40, 42.

[0034] It is to be understood, that in still further embodiments, thebrace 97 can be differently positioned. For example, the brace 97 mayextend from one of the sides of the aperture 76. Moreover, the brace mayextend inwardly from the minor flap 82 so as to push the false wall 62inwardly.

[0035] From the foregoing, one of ordinary skill in the art willrecognize that the teachings of the present invention can be employed toconstruct a wound film dispenser for wraps and the like, having improvedmanufacturability and dispensing capability, with reduced materialrequirements as well.

What is claimed is
 1. A wound film dispenser, comprising: a base havingbottom, front, and back walls, first and second ends, and an open topdefining an interior channel; a lid hingedly attached to the base; andretention walls mounted in the first and second ends of the base, theretention walls each including an aperture adapted to receive an end ofa roll of wound film, the retention walls each being non-parallel to theend walls.
 2. The wound film dispenser of claim 1, wherein eachretention wall further includes a brace positioned to engage the endwalls and angle the retention walls into the interior channel.
 3. Thewound film dispenser of claim 2, wherein the brace is a side flapextending from the retention wall toward one of the end walls.
 4. Thewound film dispenser of claim 3, wherein the side flap is wedge-shaped.5. The wound film dispenser of claim 1, wherein the end walls include amajor flap hinged to the back wall of the base and a minor flap hingedto the front wall, the retention wall being proximate the minor flap. 6.The wound film dispenser of claim 1, wherein the retention wall apertureis semi-circular in shape.
 7. The wound film dispenser of claim 3,wherein the flap extends from a side of the retention wall proximate theback wall of the base.
 8. The wound film dispenser of claim 3, whereinthe flap extends from a top edge of the retention wall aperture.
 9. Thewound film dispenser of claim 1, wherein the base, lid, and retentionwalls are manufactured from a unitary piece of material.
 10. The woundfilm dispenser of claim 9, wherein the material is die-cut single plychipboard.
 11. A wound film dispenser, comprising: a base; a coverhinged to the base; a roll of wound film within the base; and means forretaining the roll within the base, the means including false wallsangularly biased into the base.
 12. The wound film dispenser of claim11, wherein each false wall includes an aperture at least partiallysurrounding an end of the roll of wound film.
 13. The wound filmdispenser of claim 11, wherein each false wall includes a flap extendingfrom the false wall toward an end of the base.
 14. The wound filmdispenser of claim 13, wherein each flap extends from a back edge of oneof the false walls.
 15. The wound film dispenser of claim 14, whereineach flap extends from a top edge of one of the false walls.
 16. Thewound film dispenser of claim 12, wherein each aperture is semi-circularin shape.
 17. The wound film dispenser of claim 11, wherein the base,cover, and means for retaining are manufactured from a unitary piece ofmaterial.
 18. The wound film dispenser of claim 17, wherein the materialis die-cut single ply chipboard.
 19. A method of assembling a wound filmdispenser, comprising the steps of: folding a blank into a tube, thetube having first and second open ends, a top surface, a bottom surface,a front surface, and a back surface; inserting a roll of wound filmthrough one of the open ends of the tube; folding false walls into thetube, the false walls including apertures receiving ends of the roll;and folding at least one flap against each of the false walls, the falsewalls including braces engaging the flaps and biasing the false wallsangularly into the tube.
 20. The method of claim 19, further includingthe step of folding a second flap against each of the flaps.
 21. Themethod of claim 19, further including the step of folding each bracerelative to one of the false walls.
 22. The method of claim 21, whereinthe brace is folded relative to a back edge of the false wall.
 23. Themethod of claim 21, wherein the brace is folded relative to a top edgeof the false wall.
 24. The method of claim 21, further including thestep of adhering a tear strip of the blank to the front surface of theblank to form the tube.
 25. The method of claim 24, wherein the tearstrip is attached to the blank along a score line, and adhered to thefront surface at discrete areas of adhesive.